Aqueous suspension of bentonite and its use for coating thermal insulating plates

ABSTRACT

There is prepared an aqueous suspension which in addition to water, consists of 2 to 50 weight % of a mixture of bentonite and inorganic fibers, with the portion of inorganic fiber being 1 to 30 weight % and the portion of bentonite being 1 to 30 weight % and wherein the total amount of solids does not exceed 50 weight %. With the suspension there is attained an improvement of the mechanical properties of thermal insulating molded objects which are employed for thermal insulation and which for example, contain pyrogenically produced silica as a filler by delivery of this suspension on the thermal insulating plate. The suspension can also be delivered on thermal insulating molded bodies on which there is pressed a fiber net or a fiber felt. After applying the suspension several thermal insulating molded bodies can be joined together where the coating formed consisting of bentonite and inorganic fibers acts as binder. The heat insulating molded article in addition to this layer, can have one or more additional coatings based on organic or inorganic lacquer systems, silicone compositions or low melting glazes.

This is a division of application Ser. No. 481,231, filed Apr. 1, 1983,now U.S. Pat. No. 4,529,630.

BACKGROUND OF THE INVENTION

The high temperature insulating materials pressed into thermalinsulating molded articles consist of about 40 to 70 weight % of afinely divided component, such as e.g. pyrogenically produced silica, 20to 50 weight % opacifier, e.g. futile or limenite and 1 to 10 weight %of a high temperature resistant fiber, e.g. aluminum silicate fibers toincrease the mechanical stability. The thermal insulating moldedarticles likewise can have the structure of plates which have jackets,as for example, for the thermal insulation of tubes or waste gasconverters in automobiles.

They are available commercially as dry pressed molded articles (such ase.g. thermal insulating plates) of different densities (200 to 320 g/l)for this purpose usually encased in glass fiber webs (borosilicateglass) in various constructions.

The above-mentioned thermal insulating plates have a high abrasion ofmaterial and a low mechanical strength which make impossible a directworking up and assembly of the thermal insulating plates withoutadditional reinforcing material. To solve this problem it is known toembed thermal insulating plates in a jacket of plies of fiber. However,this process requires the expenditure of a large amount of energy, isexpensive and has the disadvantage that the jacket melts at atemperature treatment of 500° to 700° C., (German AS No. 2036124).

There is known according to German OS No. 2961606 a process in whichvarious binder systems are intermixed directly in the insulatingmaterial and subsequently are hardened thermally or catalytically. Thisprocess has the disadvantage that the thermal conductivity of thethermal insulating plates is increased considerably. There results fromthis a considerable deterioration not only of the insulating effect butalso of the thermal stability.

Therefore, it was the problem of the invention to find heat insulatingmolded articles for thermal insulation in which the mechanicalproperties are improved by increasing the flexural strength andresistance to abrasion. Thereby, there should not occur a deteriorationof the insulating and thermal properties of the thermal insulatingmolded articles.

SUMMARY OF THE INVENTION

The subject matter of the invention is an aqueous suspension consistingessentially of or consisting of, in addition to water, 2 to 50 weight %of a mixture of bentonite and inorganic fibers having 1 to 30 weight %inorganic fibers and 1 to 30 weight % of bentonite based on the totalamount of the suspension whereby the total amount of solids does notexceed 50 weight %, preferably 40 weight %, based on the suspension.Preferably the suspension contains besides water, 4 to 10 weight % ofinorganic fibers and 5 to 15 weight % of bentonite based on the totalamount of suspension, whereby the total amount of solids does not exceed9 to 25 weight % based on the suspension.

Besides water, the suspension can consist essentially of or consist of10 to 50 weight % of bentonite and 1 to 10 weight % of inorganic fibersbased on the suspension. Also, besides water, the suspension can consistof 10 to 50 weight % bentonite and 1 to 2 weight % of inorganic fibers,based on the suspension.

Bentonite is a known mineral. In a preferred object of the inventionbentonite consists largely of montmorillonite (see An Index of MineralSpecies & Varieties by H. H. Hey printed by order of the trustees of theBritish Association 1962).

However, there have also proven suitable suspensions which besides waterconsist essentially of or consist of 10 to 50 weight % bentonite andbetween 2 and 4 weight % of inorganic fibers. In many cases, however,there has also proven useful a suspension containing over 10 weight % ofinorganic fibers.

The fiber content of the suspension can be varied in relation to thebentonite content. It is advantageous to choose the amount of fibersproportional to the amount of bentonite.

As inorganic fibers there can preferably be used aluminum silicatefibers. The Al₂ O₃ portion thereby can amount to 5 to 95 weight %, e.g.20 to 60 weight %.

Further inorganic fibers which can be used alone or in admixture includealuminum oxide, zirconium oxide, calcium silicate, asbestos, quartzand/or silicate glasses.

A further object of the invention is the development of a process forimproving the mechanical properties of heat insulated molded articlesusing a suspension of the invention which is characterized by applyingan aqueous suspension, in a given case, repeatedly to the thermalinsulating articles, the thermal insulating articles in a given case,being dried at a temperature of 100° to 150° C.

With the help of a spraying device, which can be operated by compressedair, the suspension can be sprayed on the thermal insulating articlewhich generally consists of (or consists essentially of) a highlydispersed filler, e.g. pyrogenic silica, opacifier and fibers. Thesuspension furthermore can be applied to the thermal insulating articlesby means of immersion, rubbing, brushes, or spatulas, among others. Inthe drying even after a short time there is formed an elastic skin onthe thermal insulating article. The small addition of fibers preventsthe breaking open of the jacket. In order to attain thicker layers thespraying on the process can be repeated several times or there can beused suspensions having higher solid contents. The thermal insulatingarticles obtained by treating according to the invention have improvedmechanical properties, while maintaining the original insulation effect.

In a further illustrative form of the invention there can beadditionally pressed on the thermal insulating article a fiber nettingor a fiber felt and subsequently there can be applied the coating of theinvention. Through this there can be attained an increase in themechanical strength, especially the flexural strength.

The thermal insulating articles according to an especially practiceoriented form of the invention can be joined together one under theother in a building unit principle using the suspension of the inventionthrough which there is possible a seamless union of the thermalinsulating articles. For this purpose the suspension of bentonite, waterand fibers is applied on at least one side of the thermal insulatingarticles and these thermal insulating articles can be joined withadditional thermal insulating articles in such manner that thesuspension on drying forms an intermediate layer of bentonite andinorganic fibers which acts as a binder.

To increase the adhesive properties there can be mixed into thebentonite suspension the desired amounts of silica sol, silicate ester,e.g. methyl silicate, or ethyl silicate. Thereby the amount of additiveis regulated so that the bentonite suspension can be further processed,for example, that it can be sprayed.

In a further illustrative form of the invention there can be applied tothe thermal insulating article provided with the dried coating at leastone overcoat based on an organic or ino4rganic varnish system or a lowmelting glaze. The term "varnish" is intended to also include similarcompositions such as lacquers and enamels.

It is sufficient if an additional coating is present on the side whichafter installation of the thermal insulating article, e.g. for heatinsulation in a furnace, is the outside, i.e., on the side with thelower temperature stress. The coating is prevously dried or in a givencase, is also tempered.

Suitable materials for this type of overcoating are organic systems suchas acrylic resin varnishes, polyester varnishes, epoxy resin varnishes,alkyd resin varnishes, powder or UV hardening varnishes, includinginorganic systems, e.g. based on silicate esters or also sprayed on orsilicone coatings applied in other suitable manner. It is also possibleto employ low melting glazes, preferably, melting up to 700° C., ascoatings.

This type of overcoating of the thermal insulating article only leads topermanent and durable surfaces if the thermal insulating article ispreviously treated with the bentonite suspension of the invention. Adirect application of the abovementioned organic or inorganic coatingsto the thermal insulating article which consists of a pressed mixture ofabout 40 to 70 weight % of a finely divided component such as, e.g.pyrogenically produced silica, 20 to 50 weight % opacifier, e.g. quartzmeal, rutile or ilmenite and 1 to 10 weight % of a high temperatureresistant fiber, e.g. aluminum silicate, to increase the stability, isnot possible without the coating with the bentonite suspension accordingto the invention.

The relative flexural strength of the thermal insulating article can becontrolled by a multiple through the use of these two coatings,depending on the thickness of the overcoat. The second coating alsopermits the production of adequately stable geometric molded bodies, forexample, half shells for insulation of tubes, which previously could notbe obtained because of the unsatisfactory mechanical stability of thistype of material.

The overcoat adheres excellently to the layer made of the mixture ofbentonite and inorganic fibers lying below it. There has not beenobserved a deterioration of the insulating effect through the additionalovercoat.

A further subject matter of the invention is thermal insulating articleswhich are coated with a mixture of bentonite and inorganic fibers.Thereby the thermal insulating articles can be surrounded by a fiber netor a fiber felt upon which there is applied the layer consisting of amixture of bentonite and inorganic fibers. The thermal insulatingarticles can be joined together one beneath the other in a building unitprinciple with a layer consisting of a mixture of bentonite andinorganic fibers, whereby additionally the non-joined sides can becoated with the mixture consisting of bentonite and fibers.

On all sides or preferably on the outer sides, i.e. on the sides, whichafter installation of the thermal insulating article for heat insulatingpurposes, lie on the side with the lower temperature stress, there canbe applied additionally on the layer made of the mixture of bentoniteand inorganic fibers an overcoated based on organic or inorganic varnishsystems or even silicone compounds or low melting glazes. Thereby therecan be combined one or more layers of the same or different types ofovercoat systems.

The shape of the thermal insulating article is not fixed. In preferredillustrative forms the thermal insulating article has the shape ofplates, cylinders or hemispherical jackets (e.g. for pipes or tubularfurnaces) or also of box shaped shells, (e.g. for the thermal insulationof auto waste gas converters).

It is basically possible to provide all molded thermal insulating moldedarticles based on finely divided fillers, opacifiers, and hightemperature resistant fibers with the described coating or theadditional overcoat.

As finely divided fillers these thermal insulating molded articles cancontain pyrogenically produced metal and metalloid oxides such assilica, titanium dioxide, aluminum oxide, zirconium oxide, iron oxideand/or their mixed oxides, precipitated silicas, hydrothermally producedcalcium silicate or zeolite.

In a preferred commercial form the thermal insulating articles are madeof about 40 to 70 weight % of a finely divided component, such as e.g.pyrogenically produced silica, 20 to 50 weight % of an opacifier such ase.g. quartz meal, rutile, or ilmenite and 1 to 10 weight % of a hightemperature resistant fiber such as e.g. aluminum silicate fibers.

The described building unit assembly of these and similar thermalinsulating molded articles by means of the suspension of the inventioncan also be carried out if the thermal insulating articles have alreadybeen completely treated with the suspension.

The invention shows the following advantages:

Less material cost, very simple operating procedures.

The insulating effect of the thermal insulating articles is in no wayinjured, in contrast to known thermal insulating articles in which thebinder system is directly intermixed in the insulating material.

The temperature stability of the thermal insulating molded articles ismaintained or is even imporved. Ther thermal insulating articles after aheat treatment are not deformed or cracked. There is formed a ceramiccoating which can act against shrinkage, (with known thermal insulatingmolded articles the jacket melts after a corresponding temperaturestress and therewith hurts the insulating effect).

Through the use of the bentonite suspension as binder there is possiblea seamless processing of the thermal insulating articles.

Unless otherwise indicated all parts and percentages are by weight.

The process can comprise, consist essentially of, or consist of thestated steps with the recited materials and the compositions can consistessentially or or consist of the stated materials.

BRIEF DESCRIPTION OF THE DRAWING

The single FIGURE of the drawing illustrates the method of determiningthe flexural strength.

DETAILED DESCRIPTION EXAMPLES

The bentonite used in the examples has the following composition:

SiO₂ =57.20%

Al₂ O₃ =18.60%

Na₂ O=2.10%

K₂ O=0.40%

CaO=1.10%

MgO=2.50%

Fe₂ O₃ =3.40%

H₂ O=8.30%

Particle size <90 micrometer

Loss on Calcining: 10 wt-%

An essential criterium in the evaluation of the quality of thermalinsulating articles is above all, their thermal conductivity. However,for the evaluation there is also essential the thermal stability ofshape and mechanical strength of the thermal insulating molded articles,as well as their processability or their ability to be installed. Thetesting of the thermal conductivity, the thermal stability of shape andthe mechanical strength in the examples is carried out on round plateshaving the dimensions 100×20 mm.

Comparison Example (Without Coating) A

There was produced in a high speed mixing apparatus having a speed ofabout 5000 rpm a homogeneous mixture made from 53 weight % of apyrogenic silica having a BET surface area of 300 m² /g, 40 weight % ofa finely divided opacifier (quartz meal) and 7 weight % of a ceramicfiber based on aluminum silicate (60 weight % Al₂ O₃ portion). Themixture was pressed into plates having a weight per liter of 300 g/l andused as comparison for examples 1 to 5.

Example 1

There was produced in a high speed mixing apparaus (about 1000 to 2000rpm and 2 to 3 minutes mixing time), a homogeneous suspension made of 85weight % water, 13 weight % bentonite and 2 weight % of aluminumsilicate fibers (60 weight % Al₂ O₃). The aluminum silicate fibersbefore the mixing were ground to a fiber length of 0.5 to 2 mm. Thesuspension was applied to the surface of the thermal insulating platesaccording to Comparison Example A with the help of a spraying process.There was used a flat, wide omni-directional pistol whereby thebentonite suspension was torn apart by the injector of the atomizing airin the spray jet and thus was distributed uniformly on the insulatingplate. The sprayed plates were dried at 100° C. These thermal insulatingplates are then subjected to the following test methods:

1. Thermal conductivity in W/m°C. (Watts per meter °Celsius).

2. Shrinkage of the thermal insulating plate diameter in % at 1000° C.and a time of holding of 10 hours.

3. Relative flexural strength in Newtons, whereby the thermal insulatingplates are placed as beams on two supports and are subjected to stressthrough the concentrated load P in the middle. Thereby as shown in FIG.1:

P=concentrated load in Newtons (see the Table)

L₁ =Sample length of 100 mm

h=Sample height of 20 mm

L₂ =Width of support of 40 mm.

Through uniform increase of the load the sample is smoothly subjected tobending. In the examples carried out there was selected an increase ofthe concentrated load of 5 mm/min. The relative values for the loadingcapacity of the corresponding samples was given in Newtons.

Example 2

There were produced thermal insulating molded articles in the form ofplates according to comparison example A, whereby in the manufacture ofthe plates there were pressed on the surface of the thermal plates afiber felt or fiber fleece.

Subsequently, the thermal insulating plates were post-treated inaccordance with the process described in Example 1 with a bentonitesuspension. The relative flexural strength thereby can be increasedadditionally about 50 to 200% according to the thickness of the felt orfleece and the length of their individual fibers.

Example 3

There was produced a suspension made of 83 weight % water, 13 weight %bentonite and 4 weight % aluminum silicate fibers according toExample 1. This was applied to the surface of the thermal insulatingmolded article in the form of plates described in Comparison Example Awith the help of a spraying process. The thermal insulating article wassubsequently dried at 100° C.

Example 4

Thermal insulating articles were surface treated according to theprocess described in Example 3 and additionally coated on one side withan acrylic powder varnish.

Example 5

Thermal insulating articles were surface treated according to theprocess described in Example 3 and additionally there was melted on oneside of the surface a glaze (e.g. PbSiO₃).

Comparison Example B (Without Coating)

There was produced in a high speed mixing apparatus having a speed ofabout 5000 rpm a homogeneous mixture made of 63 weight % of a pyrogenicsilica having a BET surface area of 300 m² /g, 30% of a finely dividedopacifier (rutile) and 7 weight % of a ceramic fiber based on aluminumsilicate (60 weight % Al₂ O₃). The mixture can be pressed to thermalinsulating articles. In the present case there was chosen the form ofplates just as in Comparison Example A.

Example 6

There was produced a suspension made of 81 weight % water, 15 weight %bentonite and 4 weight % aluminum silicate fibers (60 weight % Al₂ O₃)according to Example 1. This was applied to the surface of the platesdescribed in Comparison Example B with the help of a spraying process.The thermal insulating articles were subsequently dried at 100° C. Therewas obtained a smooth and at the same time, abrasion resistant surface.

Example 7

Plates were surface treated according to the process described inExample 6. The coating consisting of bentonite and inorganic fibers thenserves as base material for an acrylic powder varnish. The varnish wasapplied to one side of the plate whereby the varnished side in assemblythe plates represented the outer side (cold side). The single sidedvarnishing sufficed to increase the breaking strength of the platesaround 2 to 3 times. The surface was smooth and free from abrasion andadditionally free from scratches.

Comparison Example C

Hydrothermally produced calcium silicate molded parts in the form ofplates having a liter weight of about 240 g/l were used as a comparisonfor Examples 8 and 9.

Example 8

There were produced a suspension from 81 weight % water, 15 weight %bentonite and 4 weight % aluminum silicate (60 weight % Al₂ O₃)according to Example 1. This was applied to the surface of the platedescribed in Comparison Example 3 with the help of a spraying process.There were obtained a smooth and at the same time abrasion free surface.

Example 9

There were surface treated plates according to the process described inExample 8. The coating, consisting of bentonite and inorganic fibers,then served as base material for an acrylic powder varnish. The varnishwas applied to one side of the plates whereby the varnished side inassembling the plates represented the outer side (cold side). Theone-sided varnishing was sufficient to increase the breaking strengtharound 2 times. The surface was smooth, abrasion resistant and inaddition, scratch free.

The values determined are set forth in Tables 1, 2, and 3.

                                      TABLE 1                                     __________________________________________________________________________                                             Shrinkage in                                Relative Flexural                                                                        Deviation of the                                                                       Mean   Thermal                                                                              Diameter of                                 Strength in N (at                                                                        Relative Flexural                                                                      Temperature                                                                          Conductivity                                                                         the Plate at                                                                           Surface                     Sample Break of the Sample)                                                                     Strength °C.                                                                           W/m °C.                                                                       1000° C. and 10                                                                 Quality                     __________________________________________________________________________    Comparison                                                                           62.9       70.6 ± 7.1                                                                          163    0.029  2.3      rough                       Example A                                                                            79.8                299    0.029           abradable                          75.6                357    0.033           surface                            64.9                465    0.041                                              69.7                                                                   Example 1                                                                            127.6      125.0 ± 8.8                                                                         162    0.029  1.2      smooth                             119.3               252    0.030           abrasion                           138.8               360    0.036           resistant                          116.1               466    0.042           surface                            123.2                                                                  Example 3                                                                            146.6               The additional coating smooth                             139.2               does not affect the    abrasion                           140.0               insulating effect      resistant                                                                     surface                     Example 4                                                                            185.0               The additional coating smooth                             185.2               does not affect the    abrasion                           178.3               insulating effect      resistant                                                                     and also                                                                      scratch                                                                       resistant                                                                     surface                     Example 5                                                                            185.4                                      smooth                             183.0                                      abrasion                           184.6                                      resistant                                                                     and also                                                                      scratch                                                                       resistant                                                                     surface                     __________________________________________________________________________

                                      TABLE 2                                     __________________________________________________________________________                                             Shrinkage in                                Relative Flexural                                                                        Deviation of the                                                                       Mean   Thermal                                                                              Diameter of                                 Strength in N (at                                                                        Relative Flexural                                                                      Temperature                                                                          Conductivity                                                                         the Plate at                                                                           Surface                     Sample Break of the Sample)                                                                     Strength °C.                                                                           W/m °C.                                                                       1000° C. and 10                                                                 Quality                     __________________________________________________________________________    Comparison                                                                           254.3               167    0.0704 1-2      easily                      Example C                                                                            246.2               276    0.0809          abradable                          239.8               388    0.0947          surface                                                497    0.1082                                      Example 8                                                                            362.2               166    0.0717 1-2      smooth                             354.5               278    0.0795          abrasion                           333.2               385    0.0936          resistant                                              498    0.1076          surface                     Example 9                                                                            564.5               The additional coating                                                                      1-2      smooth                             521.3               does not affect the    abrasion                           526.5               insulating effect      resistant                                                                     and scratch                                                                   resistant                                                                     surface                     __________________________________________________________________________

What is claimed is:
 1. A combination consisting essentially of a thermalinsulating molded article consisting of about 40 to 70% of a finelydivided insulating component, 20 to 50% of an opacifier and 1 to 10% ofhigh temperature resistant inorganic fibers and a coating for thethermal insulating article, said coating consisting essentially ofbentonite and inorganic fibers.
 2. A thermal insulating articleaccording to claim 1 wherein the coating consists essentially of 1 to 30parts bentonite and 1 to 30 parts of inorganic fibers.
 3. A thermalinsulating article according to claim 2 wherein the inorganic fibers arealuminum silicate fibers.
 4. A thermal insulating article according toclaim 1 wherein the inorganic fibers are aluminum silicate, aluminumoxide, zirconium oxide, calcium silicate, asbestos, quartz, or silicateglass fibers or a mixture of such fibers.
 5. A thermal insulatingarticle according to claim 1 surrounded by a fiber net or fiber felt andthe coating of the mixture of bentonite and inorganic fibers surroundssaid fiber net or fiber felt.
 6. A thermal insulating article accordingto claim 1 wherein a plurality of thermal insulating articles are joinedtogether in the manner of building units, the units being bound togetherby a mixture of bentonite and inorganic fibers.
 7. A thermal insulatingarticle according to claim 5 wherein a plurality of thermal insulatingarticles are joined together in the manner of building units, the unitsbeing bound together by a mixture of bentonite and inorganic fibers. 8.A thermal insulating article according to claim 7 including an overcoatof an organic or inorganic varnish or a low melting glaze on the coatingof bentonite and inorganic fibers.
 9. A thermal insulating articleaccording to claim 6 including an overcoat of an organic or inorganicvarnish or a low melting glaze on the coating of bentonite and inorganicfibers.
 10. A thermal insulating article according to claim 5 includingan overcoat of an organic or inorganic varnish or a low melting glaze onthe coating of bentonite and inorganic fibers.
 11. A thermal insulatingarticle according to claim 1 including an overcoat of an organic orinorganic varnish or a low melting glaze on the coating of bentonite andinorganic fibers.
 12. A thermal insulating article according to claim 11wherein the inorganic fibers are aluminum silicate, aluminum oxide,zirconium oxide, calcium silicate, asbestos, quartz or silicate glassfibers or a mixture of such fibers.
 13. A thermal insulating articleaccording to claim 12 wherein the article itself consists of a pressedmixture of about 40 to 70% of a finely divided insulating component, 20to 50% of an opacifier and 1 to 10% of high temperature resistantinorganic fibers.
 14. A thermal insulating article according to claim 1wherein the finely divided component is pyrogenic silica, the opacifieris quartz meal, rutile or ilmenite and the high temperature resistantorganic fibers are aluminum silicate fibers.
 15. A thermal insulatingarticle according to claim 1 wherein the coating is obtained by applyingto the article an aqueous suspension consisting essentially of water and2 to 50 weight % of a mixture of bentonite and inorganic fibers, thebentonite being 1 to 30 weight % and the inorganic fibers 1 to 30 weight% based on the total weight of the suspension, the total solids contentof the suspension not exceeding 50 weight % based on the total weight %of the suspension.
 16. A thermal insulating article according to claim15 wherein the coating is obtained by repeatedly applying the aqueoussuspension to the articles.
 17. A thermal insulating article accordingto claim 15 wherein the coating is obtained by applying the suspensionto at least one side of the thermal insulating article and then joiningthe applied side to additional thermal insulating articles and drying insuch manner that the suspension forms an intermediate binding layer ofbentonite and inorganic fibers.
 18. A thermal insulating articleaccording to claim 17 prepared by a process including the step ofapplying at least one overcoat based on an organic or inorganic varnishsystem or a low melting glaze to the thermal insulating article havingthe dried bentonite and inorganic fiber coating thereon.